The spiral sand washing machine is the core equipment for purifying and
cleaning finished sand in large-scale quartz sand production lines (with a daily
processing capacity of ≥ 3000 tons). It is responsible for removing soil, dust,
and impurities from the surface of quartz sand (with a required cleanliness of ≥
98% and impurity content ≤ 0.5%), while completing dehydration operations,
directly determining the quality level and market competitiveness of finished
sand. If there is poor cleanliness (impurity content exceeding 2%), frequent
equipment blockage (more than 3 times a week), and low operating efficiency, it
will lead to unqualified finished sand, production line material breakage, and
significantly increase production costs. Based on the characteristics of quartz
sand cleaning process, summarize a three-step optimization plan to
comprehensively improve the operational stability and cleaning effect of the
spiral sand washing machine.
Step 1: Optimize the spiral structure and wear-resistant configuration,
strengthen cleaning and conveying capabilities
The rapid wear and tear of spiral blades, improper rotation speed, or lining
plate failure are the core reasons for poor cleanliness and blockage, which
require targeted adaptation to cleaning needs.
Optimization of spiral blades and lining plates: ordinary steel plate blades
are selected. When facing quartz sand, friction and wear are fast, and the blade
thickness is reduced by more than 5mm, resulting in a decrease in pushing force;
The lack of wear-resistant lining plate causes the groove to wear out and the
cleaning trajectory to deviate. Replace the high chromium alloy spiral blades
(thickness ≥ 12mm, surface hardening treatment), improve wear resistance by more
than 3 times, and extend service life to over 1500h; Install polyurethane
wear-resistant lining plate (thickness 8-10mm) on the inner wall of the tank to
reduce material wear and minimize sand particle adhesion; Adjust the spacing
between spiral blades to 200-250mm, increase the frequency of material flipping,
enhance the adequacy of sand water contact, and achieve more thorough impurity
stripping.
Accurate control of spiral rotation speed: If the rotation speed is below
15r/min, the material flipping is not sufficient, and the soil cannot
effectively detach from the sand particles; Above 30r/min, excessive water flow
disturbance leads to the loss of fine sand and a significant increase in energy
consumption. Stabilize the speed at 20-25r/min through a variable frequency
speed control system, balancing cleaning effectiveness and resource
conservation; For quartz sand with high mud content, the rotation speed can be
adjusted to 23-25r/min to enhance the mixing and cleaning strength; Regularly
check the concentricity of the spiral shaft, with a deviation controlled within
0.5mm, to avoid incomplete cleaning caused by running shaking.
Step 2: Optimize the water flow system configuration to improve cleanliness
and anti clogging performance
Insufficient water volume, uneven distribution of water flow, or poor
drainage can lead to poor cleanliness and blockage of the tank, requiring
scientific regulation of water flow parameters.
Optimization of water inflow and flow distribution: If the inflow of a single
tank is less than 50m ³/h, it cannot effectively remove the stripped impurities;
If the water volume exceeds 100m ³/h, it is easy to cause fine sand loss; A
single water inlet leads to uneven distribution of water flow, resulting in
cleaning dead corners in certain areas. Accurately match the inflow according to
the processing capacity, regulate according to the standard of "0.8-1.2m ³ of
water per ton of sand" to ensure sufficient water volume and no waste; Install a
circular water distribution device to evenly distribute water flow along the
width of the tank, without any cleaning blind spots; Install a filter screen
(with a diameter of 5mm) at the inlet to prevent large impurities from entering
and causing blockage.
Drainage and liquid level regulation: The diameter of the drainage outlet is
too small or blocked, causing sewage to accumulate and impurities to be unable
to be discharged in a timely manner; The liquid level is below 1/2 of the tank
body, and the sand water mixture is not sufficient; If the liquid level is
higher than 3/4, it is easy to overflow water and sand. Replace large diameter
drainage pipes (≥ 200mm), regularly clean the debris at the drainage outlet to
ensure smooth drainage; Install a liquid level sensor and an automatic water
control device to stabilize the liquid level at 2/3 of the tank, balancing the
cleaning effect with the need for overflow prevention; Install a fine sand
recovery device at the drainage outlet to recover the fine sand lost with sewage
and improve resource utilization.
Step 3: Optimize feed control and pretreatment to ensure operational
stability
Overloading of feed volume, excessive impurities, or insufficient
pretreatment can exacerbate blockage and fluctuations in cleanliness, requiring
effective front-end control.
Feed quantity and uniformity control: If the feed quantity exceeds the rated
value (such as rated 500t/h, actual 600t/h), the material in the tank
accumulates, the cleaning is insufficient, and it is easy to block; Uneven
feeding leads to local overload and disrupted cleaning rhythm. Use an electronic
belt scale to accurately control the amount and maintain the feed rate at 85%
-95% of the rated value; Install a vibrating fabric dispenser to evenly
distribute materials along the width of the groove and avoid local accumulation;
Adjust the feeding speed dynamically based on the mud content, and reduce the
speed appropriately when the mud content exceeds 5% to ensure sufficient
cleaning time.
Raw material pretreatment and anti blocking optimization: Large impurities
with a particle size exceeding 100mm are mixed into the raw material, which can
easily get stuck between the spiral and the groove, leading to blockage; When
the mud content exceeds 8%, single cleaning cannot meet the standard. Install a
grid screen (with a diameter of 100mm) in front of the sand washing machine to
remove large impurities; When the mud content is high, a pre washing process is
added, which first removes most of the soil through a cylindrical washing
machine, and then enters a spiral sand washing machine for fine cleaning; Set up
maintenance ports on the side of the tank to facilitate quick cleaning of
blocked materials and reduce downtime.
Daily maintenance should pay attention to: checking the cleanliness,
equipment operation status, and drainage clarity every day; Clean up residual
materials in the tank every week and check the wear of spiral blades and lining
plates; Calibrate the spiral speed and water inflow every month, and replace
aging seals; Conduct comprehensive maintenance on the drive motor and reducer
every quarter. By taking the above measures, the cleanliness can be stabilized
at over 98.5%, the blockage rate can be reduced to less than once per month, and
the quality of finished sand in large-scale quartz sand production lines can be
guaranteed to meet the requirements of high-end fields such as construction and
building materials.